Long bar member machining apparatus and method

Description

Field of the Invention

[0001] The present invention relates to an apparatus for making a plurality of products having free-curved surfaces from an elongate workpiece, according to the preamble of claim 1, and a method therefor. Said apparatus and method are particularly suitable for machining products having thin free-curved surfaces such as a steam turbine blade.

Description of the Related Art

[0002] Conventionally, products having free-curved surfaces have been manufactured by a plurality of machine tools, some of which have simultaneously-controlled axes. As an example of the product having a free-curved surface, a blade has been used for a steam turbine. An example in which the steam turbine blade is machined will be described below. One bar member is machined by a plurality of machine tools to obtain one product (turbine blade). At machining steps, a root section is formed on one end of the bar member by a first machine tool, and a profile section (steam passage section) is then formed by another machine tool. The bar member is manually removed or attached on each machine tool (Prior art 1).

[0003] At a step of machining the turbine blade, a twisted blade should be formed on a surface, that is, a free-curved surface should be formed. Therefore, a machine tool having a plurality of simultaneously-controlled axes (four axes or more) is required. This machine tool has been disclosed in Japanese Patent Examined Publication No. HEI 5-26615, for example. Such a turbine blade has a dimension and size varied according to efficiency of the steam turbine, steam conditions and the like. For this reason, a small quantity of various products have been manufactured.

[0004] In recent years, electronic technology has been advanced rapidly. As a technique for implementing FA (Factory Automation) of a machine shop, an automatic production system such as FMS (Flexible Manufacturing System) has been developed. Such an automatic production system automatically performs delivery of a raw member, rough machining, handling, transfer, finishing and the like (Prior art 2).

[0005] According to the Prior art 1, however, it is necessary to perform two steps of machining a root section and a profile section by separate machine tools. Furthermore, works of forming the root section on the bar member and then removing and attaching the bar member to another machine tool are manually performed. Therefore, a lot of time and labor are required. In the case where the machining time taken for each step, for example, of machining the steam turbine blade or the like is short, the attaching and removing works should be performed frequently and at short interval. Accordingly, the machine operators to handle the machine tools should be stuck to the machine tools whole time other than the real handling time of the attaching and removing works. Consequently, the works have very poor productive efficiency.

[0006] According to the Prior art 2, the machining step is divided into a plurality of steps. At each step, attachment, removal and delivery are automatically performed. For this reason, when automatically attaching and removing bar member and half-machined product, whole equipment should be stopped if gripping is failed. Thus, there is a possibility that productivity might be deteriorated. In addition, in the case where a small amount of various products are manufactured, machining time for each step cannot be equalized depending on the kinds of the products to be machined. For this reason, while a machine tool used at a step taking long machining time is operating, a machine tool used at a step taking short machining time does not operate in some cases. Consequently, there is a higher possibility that an operation rate of the whole equipment might be lowered. Furthermore, a computer for controlling machine tools, a delivery system and the like is required and a program for automatically performing manufacturing steps becomes complicated so that an equipment cost is greatly increased.

[0007] Machining of other products having no free-curved surface also has these problems. DE-A-3713515 discloses a machining apparatus for machining a plurality of products having free-curved surfaces from an elongate workpiece, said apparatus comprising:

a main chuck means for gripping such a workpiece and rotating said workpiece about an axis;

a machining apparatus for machining a plurality of products having free-curved surfaces from an elongate workpiece, said apparatus comprising;

a main chuck means for gripping such a workpiece, said main chuck means having an axis of rotation and being rotatable about said axis of rotation;

a machine bed for supporting the main chuck means;

head stock means for moving a tool relative to the workpiece such that the tool can be used to shape the workpiece, said head stock means having at least three control axes, a first said control axis being parallel with said axis of rotation, a second said control axis being transverse to said first axis and substantially parallel to said machine bed and a third said axis being transverse to said first and second axes and extending upwardly with respect to said machine bed; and

control means adapted to simultaneously control movement of said main chuck means about said axis of rotation and said tool along said first second and third control axes.

[0008] The invention provides a machining apparatus for machining a plurality of products having free-curved surfaces from an elongate workpiece, said apparatus comprising:

a main chuck means for gripping such a workpiece, said main chuck means having an axis of rotation and being rotatable about said axis of rotation;

a machine bed for supporting the main chuck means;

head stock means for moving a tool relative to the workpiece such that the tool can be used to shape the workpiece, said head stock means having at least three control axes, a first said control axis being parallel with said axis of rotation, a second said control axis being transverse to said first axis and substantially parallel to said machine bed and a third said axis being transverse to said first and second axes and extending upwardly with respect to said machine bed;

control means adapted to simultaneously control movement of said main chuck means about said axis of rotation and said tool along said first second and third control axes; and

   characterised by sub-chuck means disposed opposite said main chuck means for supporting an end of such a workpiece that protrudes from said main chuck means during machining operations on said workpiece, said sub-chuck means comprising holding chuck means for gripping a peripheral surface of the workpiece at said end and pressing chuck means having a cutting portion for cutting into said end of said workpiece to support said end by a pressing force.

[0009] Advantageously, the head stock means has a swivel axis perpendicular to the axis of rotation and arranged such that such a cutting tool can swivel about said axis in the direction of said axis of rotation, and the control means is arranged to control such swivelling movement.

[0010] The apparatus may further comprise feeder means for feeding as such a workpiece to said main chuck means.

[0011] The holding chuck means may comprise two collet chucks of different size.

[0012] The holding chuck means may be rotatable about a central axis thereof with said control means being arranged to control rotation of said holding chuck means synchronous with said main chuck means.

[0013] The invention also includes a machining method comprising the steps of:

causing an end of an elongate workpiece from which a plurality of products can be made to protrude from an end face of a main chuck by a predetermined distance;

holding an end face of the workpiece by pressing the end face, and forming a support section on an end portion of the workpiece;

releasing said end face, and then gripping the periphery of the support section during rough machining of the whole profile of a product;

releasing the grip on the periphery of the support section, and then pressing and holding said end face during machining of said support section to eliminate any circumferential eccentricity thereof;

releasing said end face, and then gripping the periphery of said support section during further machining of the whole profile of said product;

releasing the said support section, and then pinching a tip portion of the product and removing the support section to define an end face of the product; and

cutting said workpiece to separate said product from the workpiece, wherein said steps are repeated to continuously obtain products from the workpiece.

[0014] The product may be a steam turbine blade.

[0015] The root section which acts as an attachment portion of the steam turbine blade may be formed in the region of said end face.

Figure 1 is a perspective view showing an example of an apparatus according to the present invention, in which the nominally vertical axis perpendicular to the longitudinal axis of the workpiece is inclined to the vertical;

Figure 2 is a perspective view showing a sub-chuck head of the apparatus shown in Figure 1;

Figure 3 is a side view of a part of the apparatus with an end of a workpiece shown protruding from the main chuck;

Figure 4 is a side view showing the protruding end of the workpiece;

Figure 5 is a side view showing the root section and a profile section of a steam turbine blade during rough machining;

Figure 6 is a side view showing a sub-chuck holding section of the steam turbine blade prior to remachining thereof;

Figure 7 is a side view showing the root section and profile sections of the steam turbine blade; and

Figures 8 (a) and (b) are side and plan views showing the steam turbine blade being separated from the end of the workpiece.

[0016] An embodiment of the present invention will be described below with reference to the drawings. In the embodiment, a steam turbine blade will be given as an example of a product. Therefore, an example in which a workpiece, hereinafter referred to as a long bar member W having a square section is machined will be described below.

[0017] As shown, a long bar member machining apparatus M comprises a main chuck head 1 for holding a long bar member W in a predetermined position and rotating the long bar member W around an axis, a machine bed 2 for supporting the main chuck head 1, a head stock assembly 3 provided on the machine bed 2, a sub-chuck head 4 provided opposite to the main chuck head 1, and a bar member feeder 5 for feeding, to the main chuck head 1, the long bar member W from which a plurality of products can be taken. The long bar member W is rod-shaped and has such a length that two or more products can be manufactured. It is sufficient that one long bar member W is continuously machined to obtain a plurality of products. This product is finished or semi-finished, and is completely machined by the long bar member machining apparatus M.

[0018] The main chuck head 1 includes a main chuck 1a having an opening 1b provided on a center thereof. The long bar member W is inserted into the opening 1b. Thus, the main chuck head 1 has a structure in which the long bar member W inserted into the opening 1b from a back side 1d of the main chuck head 1 by the bar member feeder 5 penetrates the main chuck 1a and protrudes by a predetermined distance. The long bar member W may be held by a mechanism equivalent to a chuck provided on an ordinary machine tool, or may be supported on a periphery. Furthermore, the main chuck 1a has a structure in which the long bar member W held by the main chuck 1a can be rotated around a control axis A by rotation of the main chuck 1a.

[0019] The head stock assembly 3 is provided with a cutting tool T for machining, into a predetermined shape, the long bar member W fixed onto the machine bed 2 at a predetermined distance by the main chuck 1a. For example, the cutting tool T may be a cutting tool such as an end mill cutter. The cutting tool T has such a structure as to be moved in directions of at least three control axes, that is, an X axis parallel with a longitudinal axis of the long bar member W, a horizontal Y axis perpendicular to the X axis, and a vertical Z axis perpendicular to the X axis. It will be seen that although the Z axis is referred to as a vertical axis, in fact as shown in Figure 1, the axis may be an axis perpendicular to the X axis, but inclined to the vertical. In the present embodiment, furthermore, the cutting tool T can swivel around an axis perpendicular to the Z axis in the direction of the longitudinal axis of the long bar member W. That is, the cutting tool T can swivel so as to move along a circular path B, hereinafter referred to as control axis B. A saddle 3a of the head stock assembly 3 slides along a rail 2a provided on the machine bed 2 so that the cutting tool T is moved in the direction of the X axis. A column 3c slides along a rail 3b provided on the saddle 3a so that the cutting tool T is moved in the direction of the Y axis. A swivel head 3e slides along a rail 3d provided on a front face of the column 3c so that the cutting tool T is moved in the direction of the Z axis. A spindle head 6 swivels around a predetermined axis of the swivel head 3e so that the cutting tool T swivels in the direction of the B axis. These structures are one of examples. Other structures can be used in such a manner that movement in the directions of the X, Y, Z and B axes can be performed.

[0020] Provided is a controller 12 for simultaneously controlling the straight axes X, Y and Z and the swivel axis B of the cutting tool T mounted on the head stock assembly 3 and the rotation axis A of the main chuck 1a. By simultaneously controlling these axes X, Y, Z, B and A, a product having a free-curved surface can be manufactured. If the simultaneous control axes have four or more axes including the rotation axis A of the long bar member W, the B axis is not necessary. In other words, the present invention is not restricted to the above-mentioned embodiment.

[0021] The sub-chuck head 4 has a plurality of chucks provided on a periphery as shown in a perspective view of Fig. 2. In the present embodiment, separate chucks are provided on four faces of a square support table 4b formed pivotably on the base 4a around a vertical axis. More specifically, there are provided a pressing chuck 7 for pressing and holding an end face of the long bar member W, holding chucks (collet chucks) 8 and 9 for holding the long bar member W on a periphery, and a pinching chuck (work holder) 10 for pinching a machined product. The pressing chuck 7 is provided with a protruding blade 7a having a tip formed like a cutter. The blade 7a cuts into the end face of the long bar member W by pressing force to hold the long bar member W. In the present embodiment, furthermore, two kinds of holding chucks 8 and 9 for holding the end portion of the long bar member W on the periphery are provided to correspond to a diameter of a support section which is changed while machining the long bar member W. Accordingly, the sub-chuck head 4 has a function of automatically interchanging two kinds or more shapes of the end support section of the product which is being machined until the long bar member W is machined into a finished product. The chucks 7 to 10 can be rotated at an optional speed by driving means (not shown). The base 4a can be moved in an axial direction of the long bar member W over the rail 2b provided on the machine bed 2.

[0022] The bar member feeder 5 has such a structure that the long bar member W can be inserted into the main chuck 1a from a back side of the main chuck head 1. Provided is a transfer mechanism 5a for detecting that the long bar member W is inserted into the main chuck 1a by a predetermined length and for feeding and holding the long bar member W in a predetermined position. The detection can easily be performed by using a known sensor, for example. The predetermined length can also be set easily. Holding can be performed easily if a mechanism for performing press on the periphery is provided in the same manner as a chuck provided on a known machine tool. The bar member feeder 5 is controlled to automatically draw out the long bar member W having a length necessary for machining a next product and holding the same in a predetermined position when one finished product is cut out of the long bar member W.

[0023] A carrier 11 for feeding a plurality of long bar members W to the bar member feeder 5 is provided on a back of the bar member feeder 5. In the present embodiment, three long bar members W are shown for convenience. A lot of long bar members W can further be fed continuously. Consequently, a lot of products can automatically be machined more easily.

[0024] Figs. 3 to 8 (a) and 8 (b) are diagrams showing a method of performing machining by using the long bar member machining apparatus M. As shown in Figs. 3 to 8 (a) and 8 (b), the long bar member machining apparatus M can machine a plurality of products from the long bar member W in the following manner.

[0025] As shown in Fig. 3, the long bar member W from which two or more steam turbine blades are taken is inserted into the main chuck 1a from the back on the feeding side of the main chuck head 1, and is sent from the end face of the main chuck 1a and held by the main chuck 1a with protruding at a predetermined distance.

[0026] As shown in Fig. 4, the end face of the long bar member W is held by the pressing chuck 7 of the sub-chuck head 4, and a cylindrical support section Va is formed on the end portion of the long bar member W by the cutting tool T.

[0027] As shown in Fig. 5, the support section Va is released from the pressing chuck 7 of the sub-chuck head 4, and the sub-chuck head 4 is caused to pivot so that the support section Va is held by the holding chuck 8 on the periphery. At this time, the holding chuck 8 having a greater diameter is used. The cutting tool T is simultaneously controlled with five axes by the controller 12 to roughly machine the whole root section Vb and the profile section Vc of a turbine blade. When performing rough machining by using the holding chuck 8 to finish a long steam turbine blade as a product, chattering is sometimes generated because the profile section Vc is thin. In this case, it is sufficient that the holding chuck 8 is rotated at the same speed synchronously with rotation of the main chuck 1a. In other words, the long bar member W is rotated by both the main chuck 1a and the holding chuck 8.

[0028] Milling is mainly performed for rough machining on the whole face. In the case where the profile section Vc is formed, a thickness is greatly reduced. Accordingly, fine strain is sometimes generated on the long bar member W by residual stress. In some cases, the strain causes a center of the support section Va to be shifted. If the turbine blade is completely finished with the residual stress left, the profile section Vc of the product might be deformed.

[0029] As shown in Fig. 6, the support section Va is released from the holding chuck 8 of the sub-chuck head 4 to make the sub-chuck head 4 side of the long bar member W free and the sub-chuck head 4 is caused to pivot, thus pressing and holding an end face of the support section Va of the long bar member W by the pressing chuck 7 in order to eliminate the strain of the long bar member W which is generated during wholly rough machining. At this time, since the sub-chuck head 4 side is made free and only the end face is then held by the pressing chuck 7 even if the strain is generated on the long bar member W, the long bar member W can be held co-axially with the main chuck 1a side. In this state, the support section Va formed on the end portion of the long bar member W is cut into a circle to eliminate a circumferential eccentricity generated by the strain. In the present embodiment, the support section Va can easily be machined by forming the root section Vb on the sub-chuck head 4 side which is an end side of the long bar member W.

[0030] As shown in Fig. 7, the pressing chuck 7 of the sub-chuck head 4 is released from the support section Va, and the sub-chuck head 4 is then caused to pivot, thus holding the support section Va formed concentrically with the main chuck 1a side by the holding chuck 9 having a smaller diameter. The cutting tool T is simultaneously controlled with five axes by the controller 12 so that the root section Vb forming the turbine blade and the profile section Vc are wholly finished. In some cases where the holding chuck 9 is used to finish a long steam turbine blade as a product, the product is elastically deformed in a direction of twist by a cutting load so that the predetermined accuracy cannot be obtained because the profile section is thin. In these cases, it is sufficient that the holding chuck 9 is rotated at the same speed synchronously with the rotation of the main chuck 1a. In other words, the long bar member W is rotated by both the main chuck 1a and the holding chuck 9. When machining the root section Vb of the turbine blade, special cutting tools are used. The cutting tool can be exchanged in the spindle head 6 by mounting a cutting tool exchanger capable of selectively attaching a plurality of tools in the same manner as a known machine tool.

[0031] In the present embodiment, the eccentricity of the support section Va is eliminated so that a diameter of the support section Va is reduced by cutting. Therefore, the holding chuck 9 having a smaller diameter is provided to perform gripping again. If the gripping can be performed by the holding chuck 8 having a greater diameter, the holding chuck 9 having a smaller diameter is not required.

[0032] As shown in Figs. 8 (a) and 8 (b), the support section Va is released from the holding chuck 9 of the sub-chuck head 4 and the root section Vb of the turbine blade is then pinched by the pinching chuck 10 of the sub-chuck head 4. The support section Va formed on the tip is removed and the end face is finished and cutting is performed in a predetermined position on the main chuck 1a side of the long bar member W so that a product V can be obtained. The product V can be taken from the apparatus by a handling device such as a robot.

[0033] As described above, the turbine blade product V is obtained from the long bar member W. Since the long bar member W is sufficiently long, it is caused to automatically protrude at a predetermined amount by the bar member feeder 5 and is held by the main chuck 1a. By repeating the above-mentioned steps, thus, a plurality of turbine blade products V can continuously be obtained from the long bar member W.

[0034] By using the machining apparatus M according to the embodiment, all machining steps of machining the steam turbine blade having a free-curved surface from a raw bar member can be performed. Accordingly, waiting time for each machine tool can be prevented from being generated due to a difference in machining time at each step as in the FMS. Consequently, a high equipment operation rate can be obtained. In the case where the steam turbine blades having different dimensions and shapes are selected as the products V, the different products V can continuously be manufactured easily by the single machining apparatus M if command values sent to the cutting tool exchanger and each control axis are optionally selected by the controller 12. Thus, a plurality of products V can be obtained automatically. Also in the case where plural kinds of steam turbine blades having different dimensions and shapes which can be cut out of the same long bar member W are selected as the products V, command values sent to the cutting tool exchanger and each control axis are automatically selected corresponding to the kinds of the products V by the controller 12 so that plural kinds of products V can automatically be obtained. Consequently, also in the case where a small amount of various products V are to be manufactured, productivity can be enhanced by efficient machining works. In addition, it is not necessary to attach and remove a half-machined product to and from the machine tool during machining. Furthermore, it is not necessary to deliver the half-machined product. Therefore, apparatus for automatically performing attachment, removal and delivery are not required. Thus, reliability can be enhanced and the whole apparatus can be small-sized with less increase in the equipment cost.

[0035] While the steam turbine blade has been described as an example of the product having a free-curved surface in the above-mentioned embodiment, the apparatus M can be used to machine other products having free-curved surfaces and is not restricted to the work of machining the steam turbine blade.

[0036] By using the long bar member machining apparatus, a plurality of products having free-curved surfaces can continuously be obtained from the long bar member. Therefore, working time for attachment, removal and delivery of the half-machined product can be shortened and labor can be reduced so that all the steps can be performed efficiently. Thus, productivity can be enhanced. In addition, the equipment cost can also be reduced.

[0037] If the cutting tool can swivel, a lot of cutting tools can be selected so that a free-curved surface can be machined easily.

[0038] Furthermore, the holding chuck for holding the long bar member on the periphery and the pressing chuck for pressing and holding an end face provided on the sub-chuck head, allow the removal of circumferential eccentricity on a tip support section of the long bar member. Thus, a product having high accuracy can be manufactured.

[0039] According to the long bar member machining method, a plurality of products having free-curved surfaces can efficiently be obtained from the long bar member. Therefore, all the steps can be performed efficiently to shorten working time and to reduce labor. Thus, productivity can be enhanced.

[0040] In particular, if the steam turbine blade is machined, it is possible to effciently manufacture a product having a profile section which has as a thin free-curved surface.

[0041] In addition, if the root section of the steam turbine blade is formed at the end of the long bar member protruding from the main chuck, the support section can easily be machined to eliminate strain during machining.

[0042] It will be appreciated that in the embodiment, a long bar member machining apparatus comprises a main chuck head having one control axis for holding and rotating a long bar member, a head stock assembly having three or more control axes, and a bar member feeder for feeding the long bar member to the machining position by a predetermined distance, wherein at least four axes are simultaneously controlled to obtain a plurality of products having free-curved surfaces from the long bar member.

[0043] If the long bar member fed by the bar member feeder is machined by a cutting tool provided on the head stock assembly, which has a plurality of simultaneous-control axes by means of the single machining apparatus, all steps of the machining operation can be completed so that a plurality of products having free-curved surfaces can continuously be obtained.

[0044] The embodiment is a long bar member machining apparatus comprising a main chuck head having a control axis for holding the long bar member in a predetermined position and for rotating the long bar member around the axis, a machine bed for supporting the main chuck head, a head stock assembly having at least three control axes, that is, an axis for moving a cutting tool for machining the long bar member held by the main chuck head in parallel with the longitudinal axis of the long bar member, an axis for moving the cutting tool transversely in a horizontal direction, and an axis for moving the cutting tool transversely in a substantially vertical direction, the head stock assembly being provided on the machine bed, a bar member feeder for feeding, to a feeding side of the main chuck head, the long bar member from which a plurality of products are taken, and a controller for simultaneously controlling the four axes to continuously obtain products having free-curved surfaces from the long bar member fed to the main chuck head by the bar member feeder. The above mentioned product includes a finished or a semi-finished product.

[0045] The rotation of the long bar member held by the main chuck head, and the tool provided on the head stock assembly which can be moved in directions of at least three axes, that is, the axis for movement parallel with the longitudinal axis of the long bar member, the axis for transverse movement in horizontal direction, and the axis for transverse movement in a substantially vertical direction are simultaneously controlled by the controller. Consequently, the product having a free-curved surface can be machined by the machining apparatus. Furthermore, if the long bar member obtained after cutting out the product is fed by the bar member feeder, a plurality of products can be taken therefrom.

[0046] If the control axis for causing the cutting tool provided on the head stock assembly to swivel around an axis perpendicular to a substantially vertical direction perpendicular to the longitudinal axis of the long bar member, in other words, swivel in a direction of the longitudinal axis of the long bar member W is provided, and the five axes including the swivel axis are simultaneously controlled by the controller to continuously machine products having free-curved surfaces, a degree of freedom of machining is increased so that various cutting tools can be used to form free-curved surfaces easily.

[0047] The sub-chuck head for holding an end of the long bar member fed by the bar member feeder, comprises a holding chuck provided on the sub-chuck head for holding a peripheral surface of the long bar member, and a pressing chuck for holding the long bar member by pressing an end face of the bar member. This allows operations to release the internal stress and strain in the bar member caused during the machining process and the removal of any circumferential eccentricity of the end support section by recutting the end support section.

[0048] The machining method described comprises the steps of causing an end of a long bar member from which a plurality of products are taken to protrude from an end face of a main chuck by a predetermined distance, holding an end face of the long bar member by pressing the end face onto a pressing chuck (nail center) provided on the sub-chuck head and forming a support section on an end portion of the long bar member, releasing the pressed end face, and then holding the periphery of the support section by means of a holding chuck provided on the sub-chuck head during rough machining of a product, releasing the held support section and then pressing and holding an end face of the support section during machining to remove any circumferential eccentricity generated on the support section, releasing the pressed end face, and then holding the periphery of the support section again during finish machining of the product, releasing the held support section, and then pinching a tip portion of the long bar member and removing the support section and then separating the product from the long bar member, thereby finishing the machining process, wherein said steps are repeated to continuously obtain the products from the long bar member. Consequently, a plurality of products having free-curved surfaces can continuously be machined.

[0049] If the product machined from the long bar member is a steam turbine blade, the profile section which has a thin free-curved surface can be machined efficiently, and has no machining strain.

[0050] If a root section of the steam turbine blade is formed at the end of the long bar member remote from the main chuck, the support section can easily be machined.

[0051] Although the present invention has fully been described by way of example with reference to the accompanying drawings, it is to be understood that various changes and modifications will be apparent to those skilled in the art.

Claims

1. A machining apparatus for machining a plurality of products having free-curved surfaces from an elongate workpiece (W), said apparatus comprising:

a main chuck means (1) for gripping such a workpiece, said main chuck means having an axis of rotation (A) and being rotatable about said axis of rotation;

a machine bed (2) for supporting the main chuck means;

head stock means (3) for moving a tool (T) relative to the workpiece such that the tool can be used to shape the workpiece, said head stock means having at least three control axes (X, Y, Z), a first said control axis (X) being parallel with said axis of rotation (A), a second said control axis (Y) being transverse to said first axis and substantially parallel to said machine bed and a third said axis being transverse to said first and second axes and extending upwardly with respect to said machine bed;

control means (12) adapted to simultaneously control movement of said main chuck means about said axis of rotation (A) and said tool along said first second and third control axes (X, Y, Z); and

   characterised by sub-chuck means (4) disposed opposite said main chuck means for supporting an end of such a workpiece (W) that protrudes from said main chuck means during machining operations on said workpiece, said sub-chuck means comprising holding chuck means (8, 9) for gripping a peripheral surface of the workpiece at said end and pressing chuck means (7) having a cutting portion (7a) for cutting into said end of said workpiece to support said end by a pressing force.

2. Apparatus as claimed in claim 1, wherein the head stock means (3) has a swivel axis (B) perpendicular to the axis of rotation (R) and arranged such that such a cutting tool (T) can swivel about said axis (B) in the direction of said axis of rotation, and the control means (12) is arranged to control such swivelling movement.

3. Apparatus as claimed in claim 1 or 2, further comprising feeder means (5) for feeding such a workpiece to said main chuck means (1).

4. Apparatus as claimed in claim 1, 2 or 3, wherein said holding chuck means comprises two collet chucks (8, 9) of different size.

5. Apparatus as claimed in any one of the preceding claims, wherein said holding chuck means (8, 9) is rotatable about a central axis thereof and said control means (12) is arranged to rotate said holding chuck means synchronously with said main chuck means.

6. A machining method comprising the steps of:

causing an end of an elongate workpiece (W) from which a plurality of products can be made to protrude from an end face of a main chuck (1) by a predetermined distance;

holding an end face of the workpiece by pressing the end face, and forming a support section (Va) on an end portion of the workpiece;

releasing said end face, and then gripping the periphery of the support section during rough machining of the whole profile of a product;

releasing the grip on the periphery of the support section, and then pressing and holding said end face during machining of said support section to eliminate any circumferential eccentricity thereof;

releasing said end face, and then gripping the periphery of said support section during further machining of the whole profile of said product;

releasing the said support section, and then pinching a tip portion of the product and removing the support section to define an end face of the product; and

cutting said workpiece to separate said product from the workpiece, wherein said steps are repeated to continuously obtain products from the workpiece.

7. A method as claimed in claim 6, wherein the product is a steam turbine blade.

8. A method as claimed in claim 7, wherein a root section which acts as an attachment portion of the steam turbine blade is formed in the region of said end portion of the workpiece.

Ansprüche

1. Bearbeitungsvorrichtung zur maschinellen Herstellung einer Vielzahl von Produkten mit freigebogenen Oberflächen aus einem verlängerten Werkstück (W), die Vorrichtung umfasst:

ein Hauptspannfuttermittel (1) zum Ergreifen eines derartigen Werkstücks, das Hauptspannfuttermittel weist eine Rotationsachse (A) auf und ist um diese Rotationsachse drehbar,

einem Maschinenbett (2) zum Tragen des Hauptspannfuttermittels,

Spindelstockmitteln (3) zum Bewegen eines Werkzeugs (T) relativ zu dem Werkstück, sodass das Werkzeug benutzt werden kann, um das Werkstück zu formen, die Spindelstockmittel weisen zumindest drei Steuerachsen (X, Y, Z) auf, eine erste der Steuerachsen (X) ist parallel zur Rotationsachse (A), eine zweite der Steuerachsen (Y) ist quer zu ersten Achse und im Wesentlichen parallel zum Maschinenbett und eine dritte der Achsen ist quer zu den ersten und zweiten Achsen und erstreckt sich aufwärts in Bezug auf das Maschinenbett,

Steuermittel (12) zum simultanen Steuern einer Bewegung des Hauptspannfuttermittels um die Rotationsachse (A) und des Werkzeugs entlang der ersten, zweiten und dritten Steuerachsen (X, Y, Z), und

gekennzeichnet durch gegenüber dem Hauptspannfuttermittel angeordnete Hilfsspannfuttermittel (4) zum Abstützen eines Endes solch eines Werkstücks (W), das von dem Hauptspannfuttermittel während der Bearbeitung des Werkstücks vorsteht, das Hilfsspannfuttermittel umfasst Haltespannfuttermittel (8, 9) zum Greifen einer peripheren Oberfläche des Werkstücks an dem Ende und Druckspannfuttermittel (7) mit einem Schneidabschnitt (7a) zum Schneiden in das Ende des Werkstücks, um das Ende durch eine Druckkraft abzustützen.

2. Vorrichtung nach Anspruch 1, wobei das Spindelstockmittel (3) eine Drehachse (B) senkrecht zur Rotationsachse (R) aufweist, und so angeordnet ist, dass ein Schneidwerkzeug (T) um diese Achse in Richtung der Rotationsachse schwenken kann, und das Steuermittel (12) zum Steuern dieser Schwenkbewegung angeordnet ist.

3. Vorrichtung nach Anspruch 1 oder 2, ferner mit Zuführmitteln (5) zum Zuführen solch eines Werkstücks zu dem Hauptspannfuttermittel (1).

4. Vorrichtung nach Anspruch 1, 2 oder 3, wobei die Haltespannfuttermittel (2) Spannzangen (8, 9) unterschiedlicher Größe aufweisen.

5. Verfahren nach einem der vorstehenden Ansprüche, wobei das Haltespannfuttermittel (8, 9) um eine zentrale Achse davon drehbar ist und das Steuermittel (12) zum Drehen der Haltespannfuttermittel synchron mit dem Hauptspannfuttermittel angeordnet ist.

6. Verfahren zur maschinellen Bearbeitung mit folgenden Schritten:

Hervorstehenlassen eines verlängerten Werkstücks (W), aus dem eine Vielzahl von Produkten hergestellt werden kann, von einer Endfläche eines Hauptspannfutter (1) um einen vorbestimmten Abstand,

Halten einer Endfläche des Werkstücks durch Andrücken der Endfläche und Bilden eines Stützabschnitts (Va) an einem Endteil des Werkstücks,

Freigeben der Endfläche und nachfolgendes Ergreifen der Peripherie während einer Grobherstellung des Gesamtprofils eines Produkts,

Freigeben des Griffs an der Peripherie des Stützabschnitts und nachfolgendes Anpressen und Halten der Endfläche während der Bearbeitung des Stützabschnitts zum Beseitigen jeder umfangsmäßigen Exzentrität des Stützabschnitts,

Freigeben der Endfläche und nachfolgendes Ergreifen der Peripherie des Stützabschnitts während der weiteren Bearbeitung oder Herstellung des Gesamtprofils des Produkts,

Freigeben des Stützabschnitts und nachfolgendes Einklemmen eines spitzen Teils des Produkts und Entfernen des Stützabschnitts um eine Endfläche des Produkts festzulegen, und

Schneiden des Werkstücks zum Abtrennen des Produkts vom Werkstück, wobei die Schritte wiederholt werden, um fortlaufend Produkte von dem Werkstück zu erhalten.

7. Verfahren nach Anspruch 6, wobei das Produkt ein Dampfturbinenblatt ist.

8. Verfahren nach Anspruch 7, wobei ein Wurzelabschnitt, der als Befestigungsabschnitt des Dampfturbinenblatts wirkt, im Bereich des Endabschnitts des Werkstücks gebildet wird.

Revendications

1. Appareil d'usinage pour usiner une pluralité de produits ayant des surfaces libres courbes, à partir d'une pièce d'usinage allongée (W), ledit appareil comprenant :

un moyen de mandrin principal (1) pour agripper une telle pièce d'usinage, ledit moyen de mandrin principal ayant un axe de rotation (A) et étant capable de tourner autour dudit axe de rotation ;

un banc de machine (2) pour supporter le moyen de mandrin principal ;

un moyen de tête de montage (3) permettant de déplacer un outil (T) par rapport à la pièce d'usinage, pour que l'outil puisse être utilisé pour usiner la pièce d'usinage, ledit moyen de tête de montage ayant au moins trois axes de commande (X, Y, Z) , ledit premier (X) axe de commande étant parallèle audit axe de rotation (A), ledit second (Y) axe de commande étant transversal par rapport audit premier axe en étant sensiblement parallèle audit banc de machine et ledit troisième axe étant transversal par rapport aux dits premier et second axes en s'étendant vers le haut par rapport audit banc de machine ;

un moyen de commande (12) agencé pour commander simultanément le mouvement dudit moyen de mandrin principal autour dudit axe de rotation (A) et celui dudit outil le long desdits premier, second et troisième axes de commande (X, Y, Z) ;

   et qui est caractérisé par un moyen de sous-mandrin (4), disposé en face dudit moyen de mandrin principal pour supporter une extrémité d'une telle pièce d'usinage (W) qui fait saillie hors dudit moyen de mandrin principal durant les opérations d'usinage effectuées sur ladite pièce d'usinage, ledit sous-moyen de mandrin comprenant un moyen de préhension (8, 9) de mandrin permettant de saisir une surface périphérique de la pièce d'usinage à ladite extrémité et un moyen de pression (7) de mandrin ayant une portion de coupe (7a) pour réaliser une coupe dans ladite extrémité de ladite pièce d'usinage pour supporter ladite extrémité par une force de pression.

2. Appareil comme revendiqué dans la revendication 1, où le moyen de tête de montage (3) a un axe de pivotement (B) perpendiculaire à l'axe de rotation (R) et est agencé de manière à ce qu'un outil de coupe (T) puisse pivoter autour dudit axe (B) dans la direction dudit axe de rotation et ledit moyen de commande (12) est agencé pour commander un tel mouvement de pivotement.

3. Appareil comme revendiqué dans la revendication 1 ou la revendication 2, comprenant, par ailleurs, un moyen d'acheminement (5) pour acheminer une telle pièce d'usinage audit moyen de mandrin principal (1).

4. Appareil comme revendiqué dans la revendication 1, 2 ou 3, dans lequel ledit moyen de préhension du mandrin comprend deux mandrins à pince (8, 9) de tailles différentes.

5. Appareil comme revendiqué dans une quelconque des revendications précédentes, dans lequel ledit moyen de préhension (8, 9) du mandrin peut tourner autour d'un axe central de celui-ci et ledit moyen de commande (12) est agencé pour faire tourner ledit moyen de préhension du mandrin d'une manière synchronisée avec ledit moyen de mandrin principal

6. Procédé d'usinage, comprenant les étapes consistant à :

faire en sorte qu'une extrémité d'une pièce d'usinage de forme allongée (W), à partir de laquelle une pluralité de produits peuvent être réalisés, fasse saillie depuis une face d'extrémité d'un mandrin principal (1) par une distance prédéterminée ;

tenir une face d'extrémité de la pièce d'usinage en appliquant une pression sur la face d'extrémité et former une section de support (Va) en une portion d'extrémité de la pièce d'usinage ;

libérer ladite face d'extrémité et ensuite saisir la périphérie de la section de support durant un usinage grossier de tout le profil du produit ;

lâcher la périphérie de la section de support et ensuite appliquer une pression contre la face d'extrémité, pour la tenir durant l'usinage de ladite section de support, pour éliminer toute excentricité circonférentielle de celle-ci ;

libérer ladite face d'extrémité et ensuite saisir la périphérie de ladite section de support durant un usinage subséquent de tout le profil dudit produit ;

libérer ladite section de support et ensuite pincer une portion en bout du produit et enlever la section de support jusqu'à obtenir la face d'extrémité du produit ; et

couper ladite pièce d'usinage pour séparer ledit produit de la pièce d'usinage, lesdites étapes étant répétées de manière continue pour obtenir des produits à partir de la pièce d'usinage.

7. Procédé comme revendiqué dans la revendication 6, dans lequel le produit est une pale d'une turbine à vapeur.

8. Procédé comme revendiqué dans la revendication 7, dans lequel une section de base qui sert de portion de fixation pour une pale d'une turbine à vapeur est formée dans la région de ladite portion d'extrémité de la pièce d'usinage.

Drawing